Composite metal-forsterite ceramic bodies



COMPOSITE METAL-FORSTERITE CERAMIC BODIES Original Filed Nov. 10. 1955 A. G. PINCUS 2 Sheets-Sheet 1 Nov. 29, 1960 mow. bv s mm uw o .mw uw .Q S m www vom Nw mv f: NS@

Nov. 29, 1960 A. G. PlNcus COMPOSITE METAL-FORSTERITE CERAMIC BODIES Original Filed Nov. l0. 1955 2 Sheets-Sheet 2 QQQQ Qua@

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N Inventor:

G. Pincus QQQ United States Patint l lCOIVIPOSI'IE METAL-FORSTERITE CERAMIC BODIES Alexis G. Pincus, Schenectady, N.Y., assignor to General Electric Company, a corporation of New York Original application lNov. 10, 1955, Ser. No. 546,215,A

now Patent No. 2,912,340, dated Nov. 10, 1959. Divided and this application Jan. 14, 1959, Ser. No. 786,884

s Claims. (cl. 18a-36.5) Y' -This invention relates to ceramic bodies having the mineral forsterite as the predominant constituent and,

more particularly, to novel composite structures com prising such ceramic bodies bonded to metallic bodies of a metal such as titanium. l

This is a division of my copending application SerialV No. 546,215, led November l0, 1955 and entitled Forsterite Ceramic Bodies, now Patent No. 2,912,340, dated November l0, 1959.

In the manufacture of evacuated electronic apparatus such as vacuum tubes, increasing use is being made of the metal titanium for structural elements as well as ment being exhausted or otherwise rendered inactive afterv this single operation. With the recent advent of a more plentiful and relatively inexpensive supply of substantially pure titanium, it has become economically feasible to employ titanium metal for structural elements in electronic tube construction in order that the gettering operation may extend over the life span of the tube and thereby prolong its gas-free life. In order to simplify tube construction it is desirable to extend these titanium elements through the ceramic portions of the envelope to form electrical contact with the power source, In-'av construction of this type it is necessary to provide a vacuum-tight joint between the emerging titanium metal element and the contacting ceramic portions of the envelope which also acts as an electrical insulator therefor. In use the envelope including the ceramic vpor-l tions and the elements contained therein become heated, and, of course, expand. Since apparatus of this type is usually used in an intermittent fashion, periods during which the temperature of the apparatus may reach as high as 700-900 C., are alternated with periods during which the temperature of the apparatus may drop tol room temperature or lower. Further, under the condi-A tions of operation recited above, the ceramic must have a power factor of less than 0.002 particularly in the frequency range of lo cycles, be free of gas evolving constituents, be impermeable to gases, have high elec- It usuallyA is accom` 2,962,136 Patented Nov.v 29, 1960 ICC . 2 trical resistivity, for example, and be capable of form'-, ing a strong vacuum-tight permanent bond with titanium.

Previously known ceramic bodies have been deficient in oneor more of the previously recited requirements. In particular, difficulty has been experienced in forming4 a strong vacuum-tight permanentbond with titanium.. tube structures because of the diiference in the coefficients of thermal expansion or contraction of the ceramic and titanium. Y In general, attempts to produce. such a joint in the past have fallen into twoymain,r categories. In the rst, a soft solder has been `used where the operating temperature would permit. lIn this` type of construction the sof solder material flows plastically to relieve stresses arising `from differences in ex-"f pansion and contraction of the metal and the ceramic. its disadvantages are that higher operating temperatures may not be used and, further, maximum'bake-out tern-l peratures are limited. In the second category, hard, solders having a higher melting point have been used; to permit operation at higherY temperatures. In this case, diiculty is experienced with ceramic failure. Attempts to substitute a ceramic having a sufficiently high mechanical strength to withstand the thermally induced stresses have not solved the problem in electronic apparatus, principally because these ceramics have not been Vcomposition of which will be disclosed in more detail later, having thermal'expansion and contraction char" acteristics matching those of commercial titanium metal, that bodies having this composition may be manufactur'ed to be free of gas-evolving constituents, have 'excel lent dielectric properties in the frequency range of 1010' cycles and are capable of forming strong, vacuum-tight` permanent bonds and composite structures with'titanium metal.

It is, therefore, a principal object of my invention to provide a ceramic body having a thermal coefficient of expansion substantially identical-to commercial vgrade titanium metal. f y

Further, an object of my invention is the provision5 of a ceramic body having a thermal coefcient of Yexpansion substantially identical to commercial. grade titanium metal which additionally has desirable dielectric properties at 1010 cycles, is free of gas-evolving constituents, and is capable of forming strong, vacuum-tight permanent bonds with titanium.

A still further object of my invention is the provision of a composite body comprising metallic titanium permanently bonded to a ceramic body having an'average coefficient of thermal expansion of between 9.4 and l0.4 106 centimeter per centimeter per C. in the temperature range of 25 to 700 C.

My invention Vvwill be better understood from the following description taken in connection with the accompanying drawing and its scope will bepointed out in the appended claims. A

Fig. 1 is a portion of the ternary phaseequilib'rium. diagram of SiOZ-MgO-AlzOa upon which is shownI the weight percent composition limits of the ceramicsv comprising my invention.

fFig. 2 is a sectional semi-schematic view of a vacuum' tube embodying ceramic elements permanently bonded to titanium elements.

Figs. 3 to 5 are graphical representations of the linear contraction characteristics of ceramics having compositions shown in Fig. 1 compared with titanium.

The triangular graph illustrated in Fig. l is a portion of the ternary phase equilibrium diagram of the MgO-Al2O3-Si02 system in which the compositions of the ceramics of my invention and othersof similar composition are shown for purposes of comparison. As will be apparent from inspection, the area of the SiOz-MgO-AlzOa diagram shown in Fig. l illustrates a range of compositions containing from 25 to 75 weight percent SiO2, to 50 weight percent A1203 and 25 to 75 weight percent MgO.

The forsterite ceramic bodies of my invention provide materials closely matching titanium in thermal expansion, have a surprisingly broad firing range for compositions with so few constituents and higher strength than prior art forsterites when sealed to titanium. Preferably, these bodies have a composition located within the forsteritespinel-cordierite coexistence triangle shown in Fig. l in broken lines ABC and for best results avoid protoenstatite formation and free MgO. These bodies are composed of forsterite and glass, with the appearance of spinel and then cordierite depending on rate of cooling or on a subsequent anneal around 1000 C. Preferably, these ceramics may be produced within the limits enclosed by the triangle D, E, F illustrated in Fig. 1 determined by the three compositions SiOz, percent MgO, percent A1203, percent with vtritication (vacuum tightness) over a practical fir ing range of temperatures assisted by the Fe203, TiOz, Zr02, CaO, and NaKO, normally present as impurities even in the purest grades of raw materials. These impurities, however, should not exceed a total amount of about 4 percent by Weight of the red ceramic, and preferably should not exceed 2 percent, particularly if the ceramic is to be used in vacuum tube applications.

A number of ceramic bodies having compositions within and near the above-recited limits were formed and fired at varying temperatures and times. The dielectric properties, thermal contraction characteristics and other physical properties were observed and measured and will be subsequently listed and compared.

In the preparation of these bodies, two general procedures were followed. Certain compositions were prepared from naturally occurring raw materials, i.e., talc and clay with added magnesium hydroxide while others were prepared from pure oxides, i.e., magnesium carbonate or magnesium hydroxide, which decompose to MgO upon tiring, alumina (99.9 percent A1203) and a commercial potters flint (99.9 percent SiO2) preferably in a special ultraiine grind. The naturally occurring 4raw materials, talc and clay, and the magnesium hydroxide had the following representative analyses of the listed constituents in weight percent based upon the weight of the material before `tiring. These materials also contained minor amounts of volatile substances, such as water and carbon dioxide (present as carbonates), which are lost on ignition.

4 TABLE 1 Factors used in computing analyses or batches TALCS California Montana 59. 6 62. 5 29. i) 30. 2 2.1 0. 3 0.9 1.5 nd. tr 0. 9 tr 0.5 0. 2

oLAYs Ky. l3al1 Clay Florida Kaolln 51. 7 4r. u 31.2 i 30. S 1. 2 0.5 1. 7 0. 2 0.5 0.2 0. 2 0.1 0. 9 l i). 2

MgCOa Percent Loss on ignition; 57.4 MgO. 42. o

ME(OH)2 Loss on ignition t 31. 2 MEO as. s

BaCOs Loss on ignition 22. 1 BaO 77. 9

In the preparation of compositions from these materials, the above analyses of these materials were used in preparing the bodies as is well known in the art.

Batches of the various compositions were prepared by weighing appropriate amounts of the various ingredients into a ball mill containing flint pebbles. A suflicient amount of water was added to obtain a free owing slip, the amount of water varying from about 2500 to about 3000 cubic centimeters per kilogram of dry ingredients. These mixtures were milled for about four hours. After milling the mixtures were lter pressed` dried, crushed and pulverized with appropriate apparatus. At this point, a precalcining step `may be employed if desired, as will be set forth in greater detail later. The pulverized mixtures which were to be 'formed by pressing Ywere then mixed with an appropriate amount of binder and lubricant, for example, about 7 percent of the weight of the batch of a 10 percent solution of polyvinyl alcohol in water was thoroughly mixed therewith. The mixtures were again pulverized and were formed into suitable bodies by conventional pressing operations at about six tons per square inch. The pulverized materials which were to be formed by conventional extrusion operations were mixed with a greater amount of the binder and lubricant, for example, of 40 percent by weight of the batch of a 17 percent solution of polyvinyl alcohol in water was mixed therewith to form a smooth, putty-like mass. It should be here noted that other satisfactory materials may be used n place of the recited polyvinyl alcohol solutions as a binder and lubricant. For example, glycerin has been found to function equally well.

The formed bodies were then placed in suitable open vessels upon a suitable substrate contained therein comprising sands consisting of silica, magnesia, alumina or zirconia and tired in an air atmosphere in an electrical resistance furnace.

Among many bodies prepared, batches having the foilowing nominal compositions will be more specifically disclosed and described subsequently in the disclosure.

TABLE II TABLE V Nominal compositions Fired Batch No. Condition of Fired Batch No. S101, MgO, A1203, BaO, Body percent percent percent percent Temp. C. Hours 1 55 40 6 1, 300 1 Porous. 2.-- 50 40 10 1, 350 1 Vacuum tight. 3..- 44 46 10 1, 400 1 Do. 4 43 47 10 1, 400 6 Porous. 5.-- 45 40 15 1, 300 4 Do. 6. 42 53 5 1,325 4 yD0. 7. 40 55 5 1,350 1 Do. s 40 45 15 1,350 4 Do. 9 40 41 19 1, 400 1 Stuck to placingvsand. 10. 42 49 3 1, 325 4 Porous. 11.. 50. 5 39. 0 3. 1, 350 1 vacuum tight. i21 41. 4 42. 5 16. 1, 375 1 Do. 13 l. 40 50 10 1, 400 1 D5. 14 1 42 55 3 1, 300 1 Porous. 15 1 37 49 14 1, 350 1 Vacuum tight. 16 1 35. 5 50 13. 1, 375 1 D0. v 17 l 35. 5 51. 5 13. 1, 350 1 Variable, reacted with placing sand. l 1, 375 1 Vacuum tight. 1Batches 12-17 manufactured from pure materials, Le., 20 1.400 1 Stuck t0 Sand. alumina, potters flint and magnesium carbonate. 1,350 1 POrOuS.

i, 4 Vacuum tight. Certain of these bodies were prepared from batches con- 6 11400 gg: taining the following proportions of the listed raw mate- 1, gg 13g.

, acuum t. TABLE 111 7 1,400 6 D... g

1, 450 1 Porous. i, gacuum tight.

1 0 Batch N o. Montana Talc Florida Kaolin Magnesium 1, 350 1 Vaio-:2115111 tight.

`Hydroxide s 1, 400 1 D0. 1, 400 3 D6. 1, 450 1 Do. 68. 5 11. 1 20. 4 9 1, 300 1 Porous, 60-3 10-9 2&8 1,350 1 Borderline vacuum 51, 6 22.0 26. 4 tight to porous. 42- 2 214 36- 4 1 1, 275 1 Vacuum tight. 40.0 21. 8 38. 2 0 11 325 1 D5 35. 4 32. 4 32. 2 1, 250 1 Do. 47.3 10.4 42.3 11 1, 300 1 D0. 44. 4 10. 3 45. 3 1, 350 1 D0, 28. 2 31. 6 40. 2 11 425 4 Porous.

1, 450 4 Vacuum tight. 15 1,475 4 Do. California Kentucky Magnesium Barium 1,500 4 Do.

Tale Ball Clay Hydroxide Carbonate 1,550 4 DO- 1, 600 4 Vacuum tight (overre 55 3. 3 35 6. 7 1, 450 4 Vaeum iight. 71. 1 2. 6 19. 5 6. 8 16 1, 500 4 Do. 1,550 4 D5. 1,600 4 Do. 1, 450 4 Porigls. In order to illustrate the accuracy of the actual composi- 17 Dg: tion of these bodies with their computed compositions, 1,700 4 Do. chemical analyses were performed upon specimen bodies. The following table illustrates the close agreement Vbe- Dielectric test specimens of certain of the above listed tween the computed compositions and that found upon com ositions were pre ared from disks which had been P actual analyses. pressed and tired as noted 1n Table V were tested by TABLE IV conventional techniques and the following properties were determined. Comparisons of actual and computed analyses TABLE VI 1341011 No 10 8 1 55 Fired BatcliNo. K RF. L.F. Density Com- Found Com- Found Com- Found Teom" Hours puted puted puted 41.3 41.60 39.6 39. 44 54.2 53.80 1 1,350 1 5-55 48.4 48.15 44.3 43.74 39.2 39. 44 60 1y gg() 553g) 2.7 2. si 14.7 14.65 5.o 4.89 3 40g l 3 0.6 0.81 0.8 0.79 1.2 1.23 11350 l g- 0.1 0.17 0.2 0.16 0.1 0.10 4 1,3

0.03 1 5.7 0.0 0.59 0.2 0.50 0.1 0.20 5 0.0 5.95 6 11400 1 4 0.3 n.0. o 1 0 78 0.2 0 44 65 7 gg gg 100.0 100.11 999 100.06 1000 100.10 1:45() 4 5:7 1,350 1 5.6 8 1,400 1 5.5 n 1,450 1 5.3 Pressed bodies composed of compositions listed 1n Table 10 1, 275 1 0.3 1 70 11 1,300 1 0.3 II were red as previously described at the fo lowing 1,450 4 6.3 temperatures and for the following times. After firing, 15 gg the bodies were cooled and inspected for non-continuous porosity, cracks and surface defects, such as blisters or pimples, warpage, and undesirable reaction with the plac- 7 As shown above, the dielectric properties of the several 111s Sand' forsterite bodies were measured at the three centimeter'` wavelength. YThe values fordielectric constant (K) and power factor (P.F., expressed as tan 104) were meast ured `fromspecimens of the respective bodies measuring l.000:* 0.001 inch by 0.500i`0-00l inch by quarter wave thickness employing measuring procedures and apparatus well known in the art. For a detailed description of such apparatus andiprocedures,` see Dielectric Properties of Glasses at Ultra-High Frequencies and Their Relation to Composition, Navias etal., J. Am. Ceram. Soc., 15, 234-251 (1932).

In materials of this type, it is desirable to maintain a low loss factor, LF. in Table VI, which is a product of the power factor multiplied by the dielectric constant for a given material. 1 Loss factors for materials for this type should be-less than about 0.01 andxpreferably as low as possible. In View of the magnitude of the numbers iuvolved, it is obvious that a comparatively low dielectric constant is to be greatly desired in these bodies. To compare, a test specimen from the barium-containing material of batch was tired at 1275 C. and the dielectric' constant measured at a wavelength of three centimeters was found to be 6.3, a value which is considerably higher than thatof comparative forsterite ceramics of my invention, for examplebodies'from batches 3, 4, 5, 6 (tired at 1400" C.), 7 and 8 as seen in the preceding Table VI."

I have found that thevpower factor of these materials is more directly related to composition. In general, it may be said for compositions in the area outline by the triangle D--E-F in Fig. 1 that the power factor of these bodies tends to increase with an increase in alumina content. Consequently better dielectric properties,par ticularly dielectric constant, are to be found in ceramic bodies having compositions located toward -and within the left-hand portion of the triangular area D--E-F shown in Fig. 1, and in particular within the triangular area determined by the straight lines connecting points D-G-H of Fig. 1, in which point G is a composition containing about 4l weight perCentSiOZ, 44 weight percent MgO and l5 weight percent AlZOa, and point H is a composition containing about 34.5tweight percent SiO2, 50.5 weight percent MgO and weight percent A1203. More specically, bodies prepared from batches 8, 13, 14, 15 and 16 have excellent mechanical and electrical properties.

One of the contemplated uses of the forsterite ceramics of my invention is as envelope elements of vacuum tubes. An example of such an electronicA tube is schematically shown invertical section intFig. 2 in which members 30, 3l and 32 are'formed disk-like elements of metallic titanium or zirconium oralloys thereof.` Members 33 and 34 comprise toroidal elements having central open portions 35 and 36.

Member 30 in this exemplary tube comprises an anode portion 37. Member 31 is a washer-like element having a central aperture 33 across which is provided a screenlike grid member 39 which is in electrical contact with member 31.

Member 32 comprises a cathode portion 40 which may be provided with an electrical resistance heater element 41 as shown.

The several elements 30, 31, 32, 33 and 34 are assembled into an enclosed tube body or envelope as shown. The metallic members 30, 31 and 32 are sealed to the ceramic members 33 and 34 by any known satisfactory soldering or brazing technique such as, for example, as disclosed in U.S. Letters Patent 2,570,248-Kelley, at their abutting `surfaces `after the interior formed by the communicating spaces 35, 36 and 38 has been evacuated of atmospheric and other gases and subjected to a bakeout. as is well known in the electronic tube art. Electrical connections may be provided for the anode, grid and cathode elements of such a tube through the exposed portions of members 30, 31 and 32, respectively.

It is desired to fabricate members, such as elements 30, 31 and 32, from relatively pure titanium for reasons spaanse stated previously. In view` of the thermal cycling to which such tubesaresubjectedn during operation, it is -necessary thatV thenceramic bodies from` which elements such as 33 and 34are formed have thermal expansion and contraction characteristics closely approaching those characteristics of' titanium in order that rupture of the A ceramic or of the seal between the metallic-and ceramic bodies not be broken, therebydestroying the tube., Further, the ceramic bodies must `have low 'dielectricrlosses,

' progressively poison or otherwise deleteriously affect the emission characteristics of the cathode during opera- Ation of the tube.

The'.` thermal'` expansion characteristics of ceramic bodies of my invention were measured and compared to the-thermal expansion characteristicsof metallic titanium and to ceramicbodies havingsimilar compositions.

TABLE VII Fired ThermalrExpansion Coefficient X 106 Batch N o.

Temp., Hours 25- 25- 25- 25- C. 300 C. 500 C. 700 C. 1000 C.

Titanium- 8. 5 9.2 9. 8 l10.3 1 1, 400 1 7.6 7. 4 8. 2 2 1,325 4 1. 1 1.7 3. 7 5.6 3 1, 375 1 8. 4 8. 6 9. 4 10.3 5 1,350 l 9. 7 9. 9 10.2 `10.8 6 1, 400 1 9. 7 9. 7 10. 2 10.6 7 1,400 4 9.0 9.7 10.4 11.3 8 1, 400 1 9. 6 10.0 10.3 10. 9 1, 400 3 7. 8 8.2 8. 8 9. 5 1, 450 1 8.1 9. 2 9.8 10.5 10 1, 275 1 10.2 10.4 10.6 11 1, 300 1 8. 8 9.1 9. 7 10.5 13 i 1, 400 1 8.3 8.9 9.0 10. 4

Fromthe foregoing, it may be readily seen that the bodies from batches 3, 5, 6, 7 and 8 whose compositions Y are within the triangular area determined by the straight lines connecting pointsD-E-F in Fig. l have thermal Vvexpansion and contraction coefficients very close to the corresponding coeicients for titanium, while the bodies from batches l, 2 and 10 do not have such close agreement thereto. It will be seen that body 11 whiclrhas a composition outside the triangular area D-E-F has very good expansion characteristics.

The body from batch 11 has, however, shown itself to be undesirable in that during the sealing of tubes similar to the exemplary tube of Fig. 2, the metallic titanium elements and the ceramic members exhibited a strong reaction resulting in weak bonds, discoloration of the ceramic at sealing surfaces, 'leaks and blackening of the interior of the tubes resulting in inferior tube performance at elevated temperatures encountered during operating conditions. This undesirable behavior has been attributed t0 the` high barium content of the ceramic. It has been found that the BaO content of the ceramics of my invention should not exceed l percent by weight in order to eliminate these diiculties.

In Fig. 3 a graphical comparison is made of the thermal contraction curve of ceramic bodies having the composition of batch 8 tired at diierent temperatures and times with that for titanium. The solid line curve I represents the linear thermal contraction characteristics of titanium measured in centimeters per centimeter X105 asit is cooled froml000 C. to room temperature. In the determination or" the thermal coefficients of expansion of these materials and titanium, the cooling was accomplished at the normalypower-off rate of the `furnace or slightly delayed at the rst stages of cooling. The dotted line curve identified by II represents the linear thermalcontraction characteristics of a ceramic body of the cornposition of batch 8 which had been air-fired at 1400 C. for three hours. The dashed line curve identified by III illustrates the linear thermal contraction characteristics of a ceramic body of the same composition which had been air fired at 1400 C. for one hour. The dash-dot line curve identified by IV is illustrative of the linear thermal contraction characteristics of a ceramic body of the same composition which had been air fired at 1450 C. for one hour. These curves illustrate the effect of the firing temperature and time on ceramics of this type having identical compositions.

The curves in Fig. 4 illustrate the linear thermal contraction characteristics of a ceramic body having the composition of batch 3 fired at 1375 C. for 1 hour compared to the contraction characteristics of titanium measured in centimeters per centimeter l6 while being cooled from l000 C. to room temperature. The solid line curve identified by V illustrates the linear thermal contraction characteristics of titanium while the dotted line curve identified by VI is illustrative of the behavior of a ceramic body of the composition of batch 3 under identical conditions. Solid line curve VII illustrates the linear thermal contraction characteristics of the same specimen measured 68 days later.

The curves in Fig. 5 illustrate the linear thermal contraction characteristics of a body having the composition of batch 1 and similar characteristics of a body having the composition of batch 2. The upper curve VIII shows the thermal contraction behavior of a body, batch 1, red at 1350 C. for one hour. As previously shown in Table VIII, this material has coefficients of thermal contraction for the several ranges listed which are considerably lower than titanium and further, the sharp discontinuity exhibited between 500 and 600 C. renders it unsuitable for the manufacture of bonded composite ceramic and titanium bodies for use under temperatures which cyclically vary from room temperature to 700 C. or higher.

The curve IX illustrates the linear thermal contraction characteristics of a body having the composition of batch 2. The well-defined knee in this curve clearly shows this ceramic to be unsuitable for bonding to titanium for the previously stated purposes and reasons.

As stated previously, a number of bodies having compositions within the triangular area determined by the straight lines connecting points D-E-F shown in Fig. 1 were prepared from pure materials. By using the previously described pure magnesium carbonate or magnesium hydroxide, alumina and potters flint, ceramic bodies containing small and controllable amounts of impurities may be produced. Further, by thus controlling the impurities in the composition, better control may be achieved of such properties as density, dimensional stability during firing, dielectric properties, impermeability to gases and freedom from gas evolving constituents. In order that ceramic bodies having these desirable characteristics may be consistently prepared, it has been found desirable to precalcine the constituents prior to the forming and firing operations. It should be noted that precalcination may be advantageously utilized with the naturally occurring raw materials as well as with the pure materials.

A mixture of substantially pure (commercially pure) magnesium carbonate, alumina (99.9% A1203) and finely ground commercial potters flint (99.9% SiO2) was ground in a ball mill for four hours with sufficient Water to obtain a free flowing slip. The ground batch was lter pressed and dried. The dried mixture was fired in an air atmosphere to a temperature of between 1270 C. and 1290 C. over a six and one-quarter day period. The resulting calcine was crushed and pulverized. The

powder was ground in a ball mill for eight hours with'` about 1500 to 2 000 ccs. of water per kilogram of dry mixture. The4 ground mixture was theniiltered and dried and prepared for pressing and extrusion in thesarne.

manner as the previously recited treatment for the bodies made from the natural minerals.

Bodies formed from this material had a composition corresponding to that of batch 6 and will be hereinafter referred to as batch 6. Bodies having this composition made from the precalcined pure materials were fired at 1400 C. for one hour and 1450 C. for one hour and found to be vacuum tight. Upon comparison of the properties of bodies 6 and 6' as shown in the following table it will be seen that several advantages may be attained by the use of precalcined pure raw materials.

TABLE VIII Fired Batch K Hours P.F. L.F. Density A considerable improvement in dimensional changes during firing, a higher density and a coefficient of thermal contraction which is in good agreement with that of titanium, particularly in the range 25-300 C. are achieved using precalcined pure materials as compared to bodies having the same nominal composition made from raw materials. More specifically, cylindrical rodlike elements of batch 6 composition were found to have a firing shrinkage of about 19.5 percent in diameter and 30.4 percent in height when fired at 1400 C. for one hour. Identical elements of batch 6 composition were found to have a tiring shrinkage of about 15.8 percent in diameter and 13.5 percent in height under the same firing conditions. Further, the coefficient of thermal contraction for the body having the composition of batch 6 for 25 C. to 300 C. is 8.7 10*6 cm. per cm.

per C., for 25 to 500 C. is 9.8)(10"6 cm. per cm.y

per C., for 25 C. to 700 C. is 1O.4 l06 cm. per

cm. per C. and for 25 C. to 1000 C. is 113x10-sv cm. per cm. per C. It will be seen, however, that the bodies made from the precalcined material have a somewhat higher dielectric constant. However, the power factors are low enough so that the loss factor is acceptably low.

Precalcination may be preferably accomplished in theV following manner, if desired. A mixture of magnesium carbonate or magnesium hydroxide and potters int as.

previously described may be prepared containing suilcient magnesium carbonate or hydroxide and SiOz to form the stoichiometric ratio of forsterite, 2MgO.SiO2. Upon firing with the consequent decomposition of the magnesium carbonate or hydroxide to magnesium oxide a composition of about 57.1'percent MgO and about 42.9 percent SiO2 will be achieved. This composition corresponds to point B in Fig. 1 and is substantially pure forsterite. The forsterite composition so produced may then be pulverized and mixed with appropriate amounts of magnesium hydroxide, pure alumina and SiOz or potters iiint to achieve any desired composition within triangular area determined by the straight lines connecting points D-E-F upon subsequent firing. Bodies having excellent properties may be conveniently formed by firing mixtures of the forsterite composition with alumina alone.v These bodies will have compositions lying within the lower triangular area D-G-H providing at least 1.0 weight percent and not more than 15 Weight percent A1203 is added to the forsterte composition. Greater homogeneityk may be achieved inA bodies prepared in this manner in that a maximum amount of forsterite s present in bodies prepared in this, manne; Anotheradvantase .of this method of prepara-5 accedas 11 tion is that higher calcining temperatures are practical in that there is a smaller degree of sintering rendering the calcined particles easier to crush.

In order to produce ceramic bodies according to my invention it is necessary that the composition be maintained within the limits of from about 32.5 to 46 weight percent Si02, 33 to 56.5 percent MgO and 1 to 21 percent A1203, a compositional range included within triangular area determined by the straight lines connecting points D-Ef-F of Fig. l, and preferably from 34.5 to 42.5 weight percent Si02, 44 to 56.5 percent MgO and 1 to 15 percent A1203, a compositional range included within triangular area D-G-H of Fig. 1. I have found that ceramics having compositions outside the area dened by the triangular area D-E-F in Fig. l and particularly those having compositions lying in areas in the figure above the line D-E and not stable, i.e., over a period of time, for example, the coefficient ofthermal contraction for such bodies has a tendency to change. Further, as shown by the previously discos'ed properties, the dielectric properties tend to deteriorate as the alumina content increases and compositions such as that of batch 9 containing about 20 percent or more alumina have a very narrow tiring range and tend to be porous. Ceramic bodies containing MgO in excess of those compositions lying along line D-F are undesirable because of the difficulty in obtaining vitrification upon firing. For example, vacuum tight bodies having the compositions of batches 15 and 16 were obtained when fired at temperatures between l450 and 1600 C., while bodies prepared from batch 17 were tired at temperatures as high as 1700 C. without causing vitrication. These non-vitritied bodies had very low mechanical strength and were porous.

The ceramic bodies having compositions within area D-G-H of Fig. 1 were characterized by broader iiring ranges to produce vacuum tight bodies, greater stability, coefficients of thermal expansion and contraction very similar to metallic titanium and freedom from gas evolving constituents. In addition, these ceramic bodies possess highly desirable dielectric properties and may be advantageously utilized as disclosed in the manufacture of vacuum tubes such as shown in Fig. 2 in addition to other electrical apparatus such as magnetrons, traveling wave tubes, ionization gages, power resistors, capacitors and other apparatus where the unique properties which these ceramics possess may be necessary.

New composite bodies of my present invention consisting essentially of formed and fired bodies 0f these unique ceramics permanently bonded to titanium bodies have successfully withstood many cycles of temperature variation between room temperature and temperatures of the order of 700 C. for long periods of time. Furthermore, these new ceramics have been incorporated into vacuum tubes similar in construction to that illustrated in Fig. 2 in which formed and tired ceramic bodies of my invention were permanently bonded to titanium elements to form tube envelopes having important new characteristics. These tubes were successfully operated for long periods of time under conditions which included thermal cycling between room temperature and 700 C. without developing leaks caused by continuous porosity in the ceramic or mechanical fracture thereof. Further, these ceramic tube elements showed little or no tendency to emit gases.

From the foregoing, it will be seen that I have provided new composite bodies having important new charncteristics by permanently joining metal elements to the bodies of the novel ceramic materials of my invention disclosed and claimed in my copending application Serial No. 546,215, filed November 10, 1955. While I have disclosed particular ceramic compositions and a particular metal (substantially pure titanium), it is to be understood that other particular metals such as titanium alloys aud copper and other specific ceramic compositions with'- 12` in the ranges stated above may be used successfully. I, therefore, do not desire or intend that my invention shall be limited `to these several disclosed applications and only intend to limit my invention to the subject matter of the appended claims.

What I claim as new and desire to secure by Letters Patent of the United States is.

1. A composite body comprising at least one body of substantially pure titanium permanently joined to at least one vacuum-tight vitrified ceramic body by means of a solder joint to form a vacuum-tight bond, the ceramic body consisting essentially of a tired mixture of Si02, MgO and A1203 having compositional limits within the triangular area of the ternary phase equilibrium diagram of the SiO-2, MgO and A1203 system bounded by straight lines connecting the compositions consisting of about (l) 42.5 weight percent Si02, 56.5 weight percent MgO and 1.0 weight percent A1203; (2) 46 weight percent Si02, 33 weight percent MgO and 21 weight percent A1203; and (3) 32.5 weight percent Si02, 49.5 Weight per cent MgO and 18 weight percent A1203; the ceramic body having an average coelcient of thermal contraction between 25 C. and 700 C. of about 9.4)(10"6 centimeter per centimeter -per C. to about 10.4 l06 centimeter per centimeter per C.

2. A composite body as recited in claim 1 in which said ceramic body contains less than a total of 4 weight percent of impurities consisting of oxides of iron, titanium, zirconium, calcium, sodium and potassium and less than about 1 weight percent of barium oxide.

3. A composite body comprising at least one body of substantially pure titanium permanently joined to at least one vacuum-tight vitritied ceramic body by means of 4a solder joint to form a vacuum-tight bond, the ceramic body consisting essentially of a tired mixture of Si02, Mg0 and A1203 having compositional limits within thc triangular area of the ternary phase equilibrium diagram of the Si02, MgO and A1203 system bounded by straight lines connecting composition consisting of about (l) 42.5 weight percent Si02, 56.5 weight percent MgO` and 1 weight percent A1203; (2) 41 weight percent Si02, 44 weight percent MgO and l5 weight percent A1203; and (3) 34.5 weight percent Si02, 50.5 weight percent MgO and l5 weight percent A1203; said ceramic body having an average coeiiicient of thermal contraction between `25 C. 'and 700 C. of about 9.4 l0-6 centimeter per centimeter per C. to about 10.4 106 centimeter per centimeter per C.

4. A composite body as recited in claim 3 in which said ceramic body contains less than a total of 4 Weight percent of impurities consisting of oxides of iron, titanium, zirconium, calcium, sodium and potassium and less than about l weight percent of barium oxide.

5. A composite body as recited in claim 3 in which said ceramic body contains less than a total of 2 Weight percent of impurities consisting of oxides of iron, titanium, zirconium, calcium, sodium and potassium and less than about l weight percent of barium oxide.

6. A composite body comprising at least one body or commercial grade titanium permanently joined to at least one vacuum-tight ceramic body by means of a vacuumtight solder bond, the ceramic body consisting essentially of a vitriiied mixture of Si02, Mg0 yand A1203, having compositional limits within the triangular area of the ternary phase equilibriumdiagram of the Si02, Mg0 and A1203 system bounded by straight lines connecting compositions consisting of about (1) 42.5 weight percent Si02, 56.5 weight percent MgO and 1.0 weight percent A1203; (2) 46 weight percent Si02, 33 weight percent MgO and 21 weight percent A1203; and (3) 32.5 weight percent Si02, 49.5 weight percent MgO and 18 weight percent A1203, said ceramic body being substantially free from gas-evolving constituents and having a coeliicient of thermal contraction between 25 C. and 700 C. of from 9.4 106 to 10.4 106 centimeter per centimeter per C.

7. A composite body comprising at least one body of commercial grade titanium permanently joined to at least one vacuum-tight ceramic body by means of a Vacuumtight solder bond, the ceramic body consisting essentially of a vitried mixture of SiO2, MgO and A1203 having compositional limits within the triangular area of the ternary phase equilibrium diagram of the SiO2, MgO and A1203 system bounded by straight lines connecting compositions consisting of about (1) 42,5 weight percent SiO2, 56.5 Weight percent MgO and 1.0 weight percent A1203; (2) 4l weight percent SiO2, 44 weight percent MgO and 15 weight percent A1203; and (3) 34.5 weight percent S102, 50.5 Weight percent MgO and 15 weight percent A1203, said ceramic body being vitrified to the extent that it is vacuum-tight and free from continuous porosity and not to the extent that surface defects or cracks are produced, and said ceramic body containing crystalline forsterite as the major mineral constituent and containing spinel and glass as minor mineral constituents and being substantially free from protoenstatite and free magnesium oxide and gas-evolving constituents and having a coeicient of thermal contraction between 25 C. and 700 C. of from 94x106 to 104x10-6 centimeter per centimeter per C.

8. A composite body comprising at least one body of commercial grade titanium permanently joined to at least one vacuum-tight ceramic body by means of a vacuumtight solder bond, the ceramic body consisting essentially of a vitried mixture of about 37 weight percent Si02, about 49 weight percent MgO and about 14 weight percent A1203, said ceramic body being vitrified to the extent that it is vacuum-tight and free from continuous porosity and not to the extent that warping surface defects or cracks are produced, and said ceramic body containing crystalline forsterite as the major mineral constituent and containing spinel and glass as minor mineral constituents and being substantially free from protoenstatite and free magnesium oxide and gas-evolving constituents and having a coecient of thermal contraction between 25 C. and 700 C. of from 9.4 106 to 10.4X10-6 centimeter per centimeter per C.

Ternary System MgO-Al2O3--Si02, by G. A. Rankin and H. E. Merwin from the American Journal of Science-April 1918 (pp. 301-325). 

